JP2001504398A - Porous structure and method for producing the same - Google Patents

Abstract

(57) [Abstract] A method for producing a porous structure, comprising a component providing primary separation capability, a component providing green strength reinforcement capability, a bonding capability and a thermoplastic and thermosetting polymer. Forming a dry mixture of the components selected from the assemblage; distributing the mixture to appropriate surfaces and depositing the mixture to a desired thickness; and densifying the mixture to the desired shape for the porous structure. Consolidation, removing the densified porous structure from the surface, and providing primary separation capability by melting the mixture at temperatures up to about 20 ° C above the melting point of any thermoplastic component that provides binding capacity Combining the components. The porous structure (100,110,120,125,140,175) according to the present invention comprises about 70-90% by weight of the component providing the primary separation capacity (61,62) and about 15% by weight of the component providing the green strength reinforcing capacity (64,65), From about 8 to about 20% by weight of a component selected from the group consisting of thermoplastic and thermoset polymers to provide binding capacity (67,68).

Description

DETAILED DESCRIPTION OF THE INVENTION                        Porous structure and method for producing the same Technical field   The present application relates to a porous structure for separating fluid from unwanted components. Typically , Media of this type contain auxiliary filters and are hollow, cylindrical core blocks or Or in the form of flat sheets. In use, the fluid to be separated must be porous It is directed through the filter structure, after which it is retracted. Additionally The present application provides a method for producing such a porous structure.     Background of the Invention   Typical separation media include diatomaceous earth, perlite, activated carbon, zeolites, etc. Achieve the adsorption effect filter. The use of such components in powder form is often at high pressure Generate descent and / or channeling. Therefore, the powdery auxiliary filter is , A) by incorporating them in a thin medium such as paper, or By pre-coating and depositing it thinly on the substrate to avoid under- Or b) making them useful by combining them with a binder, As a result they are subsequently built into useful porous structures.   Molded porous filter structures made from typical separation media The structure is reduced if the amount of binder is reduced from the normal 20 to 40 percent, and if The compact can be removed from the high pressure compression mold, ie if it is high Whether it is of raw strength and subsequently heat-coated in a self-supporting state Could be improved. The porous filter structure is made by an extrusion process. Such processes are slow and require a large number of extruders for commercial production. Sa Furthermore, such a process is limited to the form of useful filter structures that can be manufactured.   The filter structure can also be made by a wet or dry process. wet Examples of processing are U.S. Patents registered with Pall Corporation No. 5,443,735, which is so-called fixed carbon beds Related to the manufacture of. Several methods are disclosed, one of which is fiber material, activated carbon Mixing a wet slurry of adhesive and adhesive, and pumping the slurry into a mold. Removing the compressed blocks from the mold and extruding free water. Heating the block to remove the fractions and adding the filter material , To produce a radial flow compressed block filter. Others are fine carbon particles Flow Filling Including Mixing Process of Fine Particles and Fine Powdered Polyethylene Resin The mixture is subsequently heated to dissolve the polymer and the carbon particles are removed. Connect. The present invention provides fine brass particles to help control microbial growth in water. Based on the use of   In the drying process, the components are first dried blended, followed by the high density of the dry mixture. And different shapes and shapes due to heat treatment and heating. The drying technology described here is Illustrated in the patents below. US Patent No. Registered with Paul Corporation No. 4,664,683 describes a molded carbon block having a particle size of about 200 to 2000 microns. Teaching use. Maximum molding pressure is 400 psi. Polyethylene powder adopted The particle size of the binder is about 8 to 30 microns. Preferred coupling pressure is from 0.3 10 psi. The bonding temperature should be about 50 to 90 ° F (28 to 50 ° F) above the temperature at which the beaker softens. ° C). These temperatures are equal to or higher than the melting temperature of the binder. Lower. The mixture of carbon and binder is heated in a mold and then for 1-2 minutes. Pressurized for a while. The cooled carbon block is removed from the mold and is self-supporting I understand. The filter block does not have sufficient binding between the binder and the carbon particles. Poor physical strength due to addition I do.   U.S. Patent No. 4 registered with Amway Corporation No. 859,386 discloses a method for making a molded synthetic charcoal filter having two shells. Teaching methods, including the use of ultra-high molecular weight polyethylene as a binder, Very low media on the order of 1 gram / 10 minutes at levels between 20 and 35% by weight It has a default flow index. Bi with high melt flow index Are published as causing active site binding of activated carbon. The patent is Heating while forming block, while the block is still in the mold (From 175 to 205 ° C.) and pressurized (from 30 to 120 psi). This type of A disadvantage of the lock is the poor physical strength due to poor melt flow of the binder. At temperatures only 2-3 ° C above the melting temperature (135-138 ° C), the block will Has always weak physical strength. The method should first be avoided to improve the bond strength. The temperature from 175 to 205 ° C to increase the melt flow ing.   U.S. Patent No.5,01 registered with KT Corporation No. 9,331 teaches a similar process, which is a medium and high melt flow index To A conventional blend of binders is employed. These conventional binders Blocking the active sites at a temperature substantially above the softening point of the binder The shear forces encountered during material mixing before extruding Matrix ”(CWM). As a result, the required amount of binder is about It is greatly reduced from 8 to 20% by weight. During the extrusion process, the medium consists of cylinders and screws. Contact with. The extruded media is very hot and soft, and is subsequently handled. It must be hardened by rapid cooling to the extent possible. In the present invention A typical binder used is ethylene vinyl acetate copolymer (EVA) is sheared at a minimum of 145 ° C, at least 30 ° C above the melting temperature (115 ° C) . The binder is stretched and spread on the carbon particles to give good bonding strength You. However, this process can hide an excessive number of carbon pores. Furthermore, charcoal Element adsorption capacity and effect are very sensitive to temperature changes and shear forces of this process .   Therefore, in order to manufacture a porous structure including an auxiliary filter with a fine particle size, Attempts have been made in the past, but the technique has been developed to achieve good green strength and A block with a suitable low pressure drop should be produced during fluid separation or filtration. Smooth process to bind relatively small amount of binder resin to fine particles Did not.Summary of the Invention   It is therefore an object of the present invention to provide a method for the production of a porous structure. You.   Another object of the present invention is to comprise a separation material and a binder for fine fibers and fine particles. It is to provide a method for producing a porous structure.   Still another object of the present invention is to provide a porous structure comprising a fine separation material and a binder. Is to give.   Still another object of the present invention is to provide a porous structure which provides an adsorption and non-adsorption medium That is.   Still another object of the present invention is to provide a very large amount of material without sacrificing green strength. The purpose is to provide a porous structure consisting of a separating material and a smaller amount of a binder.   Still another object of the present invention is to provide a very large amount of material without sacrificing green strength. Provided is a method for producing a porous structure having a separation material and a smaller amount of a binder. It is to get.   At least one or more of the above objectives The perforated structure and its surroundings relating to the process of its preparation will become apparent from the following specification. The invention as described and claimed below, together with advantages over knowledge technology, Is achieved by   In general, the present invention relates to a method for producing a porous structure, the method comprising a primary separation. Ingredients that give capacity, ingredients that give strength to green strength, and thermoplastic and thermosetting properties Dry blending of components that provide a binding capacity selected from a set of polymers Forming the object and distributing the mixture on a suitable surface and stacking to a desired thickness Densifying the mixture to a desired shape for the porous structure; Removing the densified porous structure from the surface and providing a bonding capability By heating the mixture to a temperature up to about 20 ° C above the melting point of the thermoplastic component. Combining components that provide primary separation capability.   The invention also provides a porous structure, which comprises about 70% of the components that provide the primary separation capability. To 90% by weight, and about 1 to 15% by weight And a binding capacity selected from the group consisting of thermoplastic and thermoset polymers About 8 to 20 weight percent of the components that provideBRIEF DESCRIPTION OF THE FIGURES   FIGS. 1A to 1D show the compression of components in the production of a porous structure according to the invention. Provide a continuous process that represents one means for   2A to 2C show the compression of components in the production of a porous structure according to the invention. A continuous process is provided schematically illustrating the other means.   3A and 3B show various steps for the production of a porous structure according to the invention. It is a block diagram showing a combination.   FIG. 4 shows various components and processing steps for producing a porous structure according to the present invention. It is a block diagram of a combination.   FIGS. 5A and 5B show three combined microporous structures according to the invention. A continuous schematic diagram of the components is given, FIG. 5A before compression and heating, and FIG. After heat.   FIGS. 6A to 6C show two combined porosity structures according to the invention. A continuous schematic diagram of the components is given, FIG. 6A before compression and heating, and FIGS. 6B and 6C After shrinking and heating.   FIGS. 7A and 7B illustrate a method for manufacturing a porous structure according to the present invention. 7A provides a continuous schematic diagram of one component of FIG. 7A, before compression and heating, and FIG. After shrinking and heating.   FIG. 8 shows a multi-component polymer employed for the production of a porous structure according to the present invention. 8 is an enlarged cross-sectional view of the fiber taken substantially along line 8-8 of FIG.   FIG. 9 shows two multi-component polymers employed in the manufacture of a porous structure according to the present invention. Fibers are shown, with the outer polymer sheath portion from each fiber fused together.   FIG. 10 is a partial side view of a porous structure according to the present invention.   FIG. 11 is an enlarged view of a region surrounded by a circle in FIG.   FIG. 12 is a partial side view of another porous structure according to the present invention.   FIG. 13 is a partial side view of another porous structure according to the present invention.   FIG. 14 shows a portion of another porous structure according to the invention having one closed end. FIG.   FIG. 15 shows a plurality of detachable three-pieces for manufacturing a multilayer cylindrical porous structure. FIG. 7 is a side view, partially in section, showing the mold associated with the boss.   FIG. 16 shows a multilayer cylindrical porous structure product according to the present invention. FIG. 6 is a partially sectional side view showing a part of FIG.   FIG. 17A relates to the schematically illustrated apparatus for the production of a multilayer cylindrical porous structure. It is a side view of a partial section showing a model.   FIG. 17B is a partial cross section showing a mold as shown in FIG. 17A partially filled. FIG.   FIG. 17C shows a densified multilayer cylindrical porous structure, as shown in FIGS. 17A and 17B. It is a side view of the partial cross section which shows a mold.   FIG. 18 is a schematic view of an apparatus for manufacturing a multilayer flat sheet porous structure according to the present invention. FIG.   FIG. 19 is a cross-sectional view of a part of a multilayer flat sheet porous structure product according to the present invention. .   FIG. 20 is a perspective view of a non-fibrillated fiber employed as a component of the porous structure of the present invention. FIG.   FIG. 21 is a diagram showing the slope of the fibrillated fiber component used as a component of the porous structure of the present invention. FIG.   FIG. 22 shows the effect of the green strength of the porous structure according to the present invention and the polyethylene fiber additive. It is the graph which compared the increase of fiber.     Preferred embodiments for carrying out the invention   The present invention relates to a porous material useful for separation, especially for filter applications. For the manufacture of structures and for new and useful shapes of blocks and other configurations Related. The porous structure is composed of: 1) a component providing a primary separation ability, or a primary medium (P M), 2) a component that provides green strength reinforcement or a green strength reagent (GSA), and 3) binding capacity It consists of a component that gives strength or a binder (B). One or more Each component of the ip can be combined. Additional component (4) is described below. Contains various additives. Usually, additional additives are key functions of PM, GSA and B Does not change. However, when the contribution of the additive is large, the additive is PM, GSA, And / or part of B.   With respect to the primary separation medium, it can be a mixture within the mixture acting as a porous matrix. One or more types of particles or fibers. Preferably, the primary medium Consists of carbon particles, diatomaceous earth, perlite, activated alumina, silica, natural fibers, and It is selected from a set consisting of artificial fibers. Typically, a porous carbon block structure is formed. Powdered carbon was selected to produce a 10 to 400 micron particle size. Consists of is A general description of suitable carbons is incorporated herein by reference. See U.S. Patent No. 4,859,386. Activated carbon Available from Calgon, Bamebey and Sutcliffe. Generally other particle media The size for the body is well known to those skilled in the art and is therefore Does not constitute. Similarly, fiber dimensions, ie denier, length, diameter Are well known for the production of various porous structures based on fibrous media. Can be   With respect to fibers, natural species include cellulose such as cotton and wood pulp, wool , Jute, hemp and artificial species include polyester, carbon, graphite, glass, Krill, rayon, nylon and aramid fibers as well as polyethylene Monomers having from 2 to about 5 carbon atoms, such as ren and polypropylene Including polyolefin fibers. In some cases, polypropylene or polye Multi-component fibers with a stell core and a lower melting polyethylene sheath Selected as discussed below. Such fibers are commercially available One example consists of a high density polyethylene (HDPE) sheath and a polypropylene (PP) core. You.   The primary medium is also polystyrene, polyvinyl chloride, polycarbonate, polyzulph. , Nylon and poly Not only esters but also carbon atoms such as polyethylene and polypropylene Certain plastics, including polyolefins derived from monomers having With powder. Clearly, some primary media are either unmelted or It does not melt at least during the manufacture of the porous structure, but other species may be partially or wholly Melts as If the primary medium does not melt, an adsorbed porous medium is created. However , Both adsorbed and non-adsorbed porous media, as described in more detail below, And non-melted primary media.   Examples of non-melting or non-melting primary media are activated carbon, ion exchange resins, Contains mina and zeolites. The non-adsorbing, non-melting or non-melting primary medium is natural and Contains synthetic fibers. Examples of non-absorbable media made from fusible primary media are multicomponent fibers including.   For the raw strength reagent, fibers and powders are employed. Straight or broken Bent fibers are less effective than fibrillated fibers. Soft fibers are better than hard fibers It is effective. Suitable fibers are polyethylene and polypropylene, polyester, na From a collection of polyolefin fibers, such as iron, aramid and rayon The selected fibrils or microfibers. These fibers, depending on their physical and chemical properties and porosity, may be melted. Can additionally function as a binder or as part of a porous matrix be able to. The preferred diameter of these types of fibers is less than 100 microns, Not limited to that. The amount of green strength reagent and compression pressure are process variables for a particular formulation. is there.   Other types of strength reagents include liquid strength reagents such as latex and resin solutions. Including. Styrene-butadiene, poly (ethylene-vinyl acetate) and acrylate salt Ip's latex is a good candidate. Methylcellulose, hydroxypropyl Methylcellulose, carboxy methylcellulose, hydroxyethylcellulo Source, polyvinyl alcohol, polyvinyl pyrrolidone, polyacrylic acid, polyether Tylene oxide, polyethyleneimine, polyacrylamide, natural rubber and it Aqueous resin solutions made from water-soluble polymers such as the copolymers and derivatives thereof In addition, they are employed separately or in combination. To improve the green strength, use a very small amount Of water is phenol-formaldehyde and melamine-formaldehyde resin Used to soften such dry powdered thermosetting binder resin Therefore, water is adopted as a fresh strength reagent.   The binder material is in the form of powder or fiber or a mixture thereof, And thermosetting plastics are preferred. Fibrous binder contains multiple components and small It contains fibrous fibers and has some separation properties. The binder is physically Time required to improve strength, reduce melt flow, and heat bond media It is preferred to have an intermediate melt index to reduce Suitable method The index is 1 per 10 minutes for the adsorption and absorption media (according to ASTM 1238). Greater than grams and up to about 20 grams per 10 minutes.   In particular, powder materials include epoxy, phenol-formaldehyde and melamine. Not only formaldehyde resin powder but also polyethylene and polypropylene Monomers having from 2 to about 5 carbon atoms, such as polyolefins such as It is selected from the set consisting of the resulting polymer powder. Such polymer powder is 1 It has a particle size on the order of 0-40 microns. For example, fibrous binders Polyethylene and polypropylene and various geometries and polymer combinations A multi-component fiber that combines two carbon atoms Including polymeric fibers such as polyolefins formed from monomers having about 5 . Often the length of such types of fibers is less than 0.5 inch (1.27 cm). A preferred length is no more than 0.25 inches (0.64 cm). The preferred fiber diameter is 200 microns It is as follows.   Ethylene vinyl acetate, polystyrene, polyvinyl chloride, polyacetate, polish Additional thermoplastic polymers such as rufone, polyester and nylon Used as a dagger. Do crystalline polymers often give better physical strength? Gives a better defined melting temperature. Amorphous polymers have melting temperatures do not do. The best way to select the firing temperature is from 5 ° C to 20 ° C above the glass transition temperature. Experiment up to ° C. Melting and glass transition temperatures are determined using DSC. Or obtained from the supplier.   In addition to the above components, the porous structure of the present invention also includes a cationically charged resin, Replacement material, perlite, diatomaceous earth, activated alumina, zeolite, resin solution, latek Materials, metal materials and fibers, cellulose, carbon particles, carbon fibers, rayon fibers, nylon Ron fiber, polypropylene fiber, polyester fiber, glass fiber, steel Additional components such as fibers and graphite fibers Or include additives to provide additional properties and features, or Include their mixtures to reduce weight. Polypropylene, polyester, Many fibers, such as nylon, glass, carbon, steel and graphite, are scratched. It is a good candidate for improving tension and impact strength. Such additional components Minutes range from about 0.1 to about 90% by weight, with concomitant reduction in the amount of primary medium .   Some additional components may also function as primary separation media or biostrength reagents, It is therefore present in the mixture from which the porous structure is produced, If the separation medium or fresh strength reagent is not the same as the additional When the medium is diatomaceous earth and the additional component is carbon fiber, or a biostrength reagent Are polyolefin fibers, and the additional component is glass fiber. Is adopted.   Cation-charged resin is sprayed directly onto particulate media such as diatomaceous earth and carbon Is done. These treated media may be larger in water separation or filtration. Adsorbs small anionic fine particles that have an effect. Such resin is here for reference Discussed in old patents owned by the assignee of record, incorporated as literature Came. For example, they are melamine, formaldehyde, cation, colloid denatured U.S. Pat. Nos. 4,007,113 and 4,007,114 for media, Cat. U.S. Patent No. 4,305,782 for id-silica modified fibrous and particulate elements No., and treated with epichlorohydrin-polyamine and polyamide cation resin U.S. Patent No. 4,309,247 relating to cellulose fibers and particulate media.   The preferred method for practicing the present invention is that which opposes wet application or wet treatment The drying of the components. In the drying process, components are first dried Followed by distribution of the mixture on a suitable surface at ambient temperature. Used here The definition of “appropriate surface” is to build a dry mix of the desired thickness for later processing or Including depositing inside the mold as well as on other surfaces that allow it to be established. mixture If is deposited into the mold, the desired thickness is essentially obtained by filling the mold. You. As explained below, the mixture is also distributed uniformly on the flat surface at the desired thickness. Is done. Therefore, the execution of the method of the present invention is limited by whether or not to use a type. Not something.   The definition of “dry” includes the minimum amount of liquid in the blend. No. This amount of liquid requires having dripping liquid or different handling Appearance and physical properties to become a "wet" blend or process defined as Does not significantly change handling. Therefore, the method of the present invention is a Does not involve tree formation and therefore requires other steps for exhaust or liquid removal is not.   The particle size distribution of the mixture depends on the presence of fibrillated fibers throughout the structure. Very uniform retention. In other words, fibrillated fibers are divided into large and small particles. Hinder separation or migration. The blend at this stage has no green strength.   The next step of the method according to the invention is to dry the laid mixture into different forms and shapes. It is to increase the density. Such methods include calendering, compression molding, Includes ton molding, injection molding, isostatic pressing and extrusion. When the mixture is deposited inside the mold It is densified by piston molding, balanced compression, etc. Similarly, mixed If the object is distributed on a flat surface, it may be calendered or otherwise compressed. Compressed and densified and used when flat sheet media is desired. To form a flat sheet, or to have a properly configured porosity Disc-shaped members are punched from such sheets for ultimate use in structures. Be pulled out.   Equilibrium compression involves either wet bag or dry bag processing. As you know In addition, both methods apply water simultaneously and uniformly to all surfaces of the part being formed. Employ a chamber filled with liquid applied under pressure. Powdering to be compressed The material is partly functioning as a mold and at the same time a barrier against hydraulic liquids. Caps fit into a formed membrane known as “bag tooling” It is cellized. Uniform pressure ensures accurate bag-tooling of powder from all directions Compress to a perfect shape.   In the wet bag method, the powder is loaded into a rubber mold. Loaded Later, the mold is sealed and water pressure is applied. Once compression is achieved, the type is The reopened and compressed parts are removed.   In the dry bag tooling method, hydraulic fluid is applied to the mass inside the pressure chamber. Sealed by a drying bag, which is inserted with a separate tooling drying bag. Be in this master bag to be filled. For this method, the material is a tool bag After being loaded into and pressurized, the tool bag is removed from the pressure chamber You. The dry bag method simplifies operation and increases production speed. Dry bag Compression is preferred despite the non-limiting means of providing a densification step. You.   Referring to FIG. 1A, a dry stacked mixture of porous structures forming component 20 Is supplied into a bag 21 which is a rubber mold and is held in a pressure vessel 22. The Vessel 22 provides a hydraulic chamber 23 to compress mold 21. In FIG. 1B The vessel is closed by a cover 24 by suitable means (not shown), Thereafter, the rubber mold 21 is compressed in the chamber 23 (FIG. 1C). Raw, according to compression Article 25 is of sufficient strength to be self-supporting without external molds as shown in FIG. 1D. The pressure on the bag 21 is released, the vessel 22 is opened, and the product 25 is It is removed by any suitable means, such as ram 26. Rubber mold filling is generally a number This is achieved with the aid of a hopper or similar filling device indicated at 28. That Such a device distributes a mixture of components 20 uniformly, quickly and in a measured amount inside a mold. Must be able to Those skilled in the art will no longer understand such devices. Is unnecessary. Of course, the above description together with FIGS. It is illustrative and simplified for explanation of one type of operation.   As noted above, the dry, stacked mixture of porous structures forming component 20 may also be present. Supplied on a flat surface. Alternatively and with reference to FIG. 2A, such a flat surface 30 Consists of a movable belt which is suitably supported and passes through a calender 31. mixture The object is first given the desired thickness as shown on the left side of the calender in FIG. 2A. Is deposited. Then it forms a densified sheet of raw product 34 It is conveyed between the calender rolls 32 and 33 which oppose each other. At this stage , Sheet 34 is removed from first side 30 and fed to press 35, schematically shown in FIG. Thus, a lower supporting platen 36 and an upper pressing platen 38 are provided. The latter is a disc young Or multiple smaller bioporous media products, such as other suitably shaped media. A plurality of dies 39 to be stamped or punched are provided. After that, the raw disk 34 is further Transported to oven 40 for processing.   The continuous process is schematically illustrated in FIGS. 2A and 2B, with surface 30 being the lower platen of the press. It can be understood that it can also be. Calendar device 31 produces a mixture of components 20 raw Upper platen that compresses and densifies 34 sheets (Not shown). Of course, the ultimate shape and desired porous media Subsequent blanking of the raw product is specified by the body, so the sheet itself is In a plate or frame device without being subjected to the cutting operation shown in B It can be configured for use.   After the formation of raw product 25 or 34, the next step is above the melting point of the polymeric binder. The primary medium is bound by melting the binder in the porous structure at a temperature of To maintain self-supporting conditions. This is again a raw disc product 34 Are schematically illustrated in FIG. 2C. Preferred temperature is 20 ° C above the melting point of the binder And more preferably up to 10 ° C. above the melting point. For example, FA700 (Quantum USI) Temperature and time for 13040F (MiniFiber) high density polyethylene binder Approximately 140 ° C (~ 5 ° C above melting point and ~ 15 ° C above beaker softening temperature) And 40 minutes. (The melting point of the binder is determined by a differential scanning colorimeter at 5 ° C / min. Is done. ) At this heating temperature, the porous structure causes high melt flow problems. To provide the highest physical strength and to block the pores of the primary adsorption separation medium, such as activated carbon. And reduce their abilities and effects Is believed.   In addition to the above features, the porous structure is self-supporting during the heat treatment. Also the raw strength test Drugs impart thermal strength to the porous structure. The best combination of time and temperature is Vine Depends on the type or mixture of brewers. The best conditions are the minimum melt flow and It gives the highest physical strength in the shortest amount of time. Microwave, radio frequency And other temperature bonding processes such as infrared heating. Unlike existing technologies, There is no shear force applied to the medium during the firing process. Ultra high molecular weight polymer -No binder is used.   Heat the raw product 25 sufficiently to melt or react the binder. Is a preferred process, but the present invention also provides a Alternatively, a method in which a separation heating step is not required is included. Generated by compression only Examples of such products made are given in Examples 1 to 20 below.   In Table 1 below, taught by three patents summarized in the background of the invention And the method of the present invention assigned to Cuno, Inc. Differences from the law are listed. The first three prior art products are thermally coupled. One before or during He was not self-supporting.  Multiple layers of separation media can be made by calendering, compression or equilibrium compression You. The blend of each layer should create a multi-layer porous structure under various compression conditions. Are continuously applied and pressed. In the case of equilibrium processing, Are added simultaneously through feeders attached to the concentric mouths. The fee The hopper moves upward during filling without disturbing the separating layer. Or the filling process is different This is accomplished by removing the sleeve after the components have been added.   Addition equal to about 1% of high-strength fiber material greatly improves physical and impact strength You. This type of composite structure reduces cracking of the product during shipping and handling, and Improve product reliability. Polypropylene, polyester, glass, carbon and Many fibers, such as graphite fibers, are good candidates for such purposes . If too much fiber material is used in the product, the medium becomes very fuzzy When processing becomes difficult, it is preferable to pre-compress the medium. Pre-compressed lumber The shape of the material can be many, such as sheets, rods, tubes, pallets, and briquettes. It is compressed into a shape.   Another advantage of balanced compression is the different shapes of the porous structure Or to make a pattern. In particular, grooves in different shapes are bag touring Is designed directly on the surface of the porous structure when it is designed to have the opposite pattern. You. Surface grooves improve dust retention capacity in separation applications. Furthermore this method Has a hollow central core that is sealed at one end when a shorter central pin is used A typically cylindrical porous structure is made. This type of product is a typical cylindrical Required to attach end caps to the ends of Remove materials and methods.   Densification through balanced compression is another advantage of L / D (length vs. 3: 1) greater than 3: 1. To form a porous structure having a diameter) ratio, which is the axial density gradient created inside the structure. The conventional method of axial compression in which L / D is limited to 2 to 3: 1 due to practical problems Contrast with columns.   In summary, the main components in the porous structure formulation are: 1) primary medium (PM), 2) green strength test. Drug (GSA), 3) binder (B), and 4) additional additives. Usually additional additives Does not change the main functions of PM, GSA, and B. However, when the contribution of additives is large, The additives can be part of PM, GSA, and / or B.   Before proceeding with the examples which illustrate the practice of the present invention, We need to summarize again. Therefore, in some cases, excluding additional components, There are three independent components of These are shown in box 50 in FIGS. 3A and 3B. Thus, it contains the primary medium PM, the raw strength reagent GSA and the binder B. These components are the most First dry mixed, then compressed in box 51, removed in box 52 and added in box 53 in FIG. 3A. Heated or not heated as shown in FIG. 3B. Both methods are illustrated in FIG. 3A. Non-adsorbed and adsorbed porosity shown in boxes 54 and 55 and boxes 56 and 58, respectively, of FIG. 3B. Manufacture a structure, for example a filter or a separation medium.   Focusing on the method schematically illustrated in FIG. 3A and referring to FIG. The body contains both powder 61 and fibers 62. The binder material in box 63 is also powder 64 and Contains both fibers 65. Finally, the raw strength reagent in box 66 also contains powder 67 and fiber 68. No. To simplify the explanation at this stage, the resin solution, latex and Non-powder and non-fiber component species, such as water, are always hindered by their presence It is not shown in FIG. 4 with the understanding that this is not always the case. To be considered in Figure 4 The point is that the finished product 69 results from a combination of powder and fiber, for example PM powder 61 , B powder 64 and GSA fiber 68 And a mixture of three fibers, PM62, B65 and GSA68.   Ensure that PM powders and fibers are generally unmelted, but selected from fusible materials. Must be taken into account. Similarly, B powder and fiber are meltable, while The GSA powder and fibers can be selected from non-melting but fusible materials. Even better Also, it is always necessary to choose three independent components to give PM, B and GSA is not. For example, the fiber selected for PM is GSA for two-component product 69. If the fiber adopted as a fiber or selected for PM is a multicomponent fiber (HDPE / PP) In that case, it is adopted as B and GSA for one component product 69 etc. Likewise , The present invention relates to one or more PMs and / or one or more Bs and / or one or more GSAs. Performed with a mixture, the porous structure 69 and the method of the present invention are therefore a single PM component. It is understood that it is not limited to the combination of the single B component and the single GSA component .   Nevertheless, even if initially two or three components are The porous structure of the present invention, even when provided in the mixture by PM in cents, B in weight percent between 8 and 20, and weight percent between 1 and 15 Consists of the GSA of the United States. B young If any of GSA is a resin solution or the like, it is not shown in FIG. Powder and / or powder for M and for at least one other ingredient B or GSA It is further possible to select fibers or fibers.   5-7, a further description of the invention will be made for three exemplary component mixtures. It is abbreviated. In FIG. 5A, PM80, B81 and GSA82 are first shown. You. In FIG. 5B, after the mixture has been compressed and heated, only the segments The product 83 shown consists of identifiable PM80 and GSA82, while the binder 81 Holding the other two ingredients together to be melted and form product 83 It should be noted that A typical example (Example 41) is to use carbon particles as PM and GSA. And a polyethylene powder as B. After thermal bonding, The propylene fiber acts to increase the structural strength of the porous product 83.   In FIG. 6A, the mixture contains PM90 and fibrous components that function as GSA and B. And a second component 91. In FIG. 6B, the mixture was compressed and heated Later, part of the fiber 91 melts and the remaining fiber (GSA) and PM are combined together in the product 93 It should be noted that a binder 92 is formed to form the binder. A typical embodiment is a PM As carbon black, and fiberized into small fibers as GSA, for example, PE and B ( Examples 17 to 20) are included. FIG. 6C shows complete melting of fiber 91, resulting in a primary medium. Body 90 and binder 92 remain. Depending on the components selected, product 93 is shown in FIG. B or FIG. 6C.   In FIG. 7A, the mixture consists only of fibers such as multi-component HDPE / PP fibers 91 . These fibers give PM, GSA and B (Example 47). In FIG. 7B, After these fibers have been compressed and heated, some of the fibers melt and the When the main fiber is PM95, the fiber matrix matrix of product 94 is formed. Network. A typical example is the compression and compression of multicomponent fibers such as HDPE / PP. Product resulting from heating and heating. Such fibers are shown in FIGS. 8 and 9, where The inner core 96 is PP and the outer sheath 98 is HDPE. In FIG. After the fiber 91 is heated, the spliced fiber provides both separation capacity and green strength. A portion of the sheath 98 melts together to form a matrix.   With reference to FIGS. 10 to 13, several types of manufactured according to the present invention are illustrated. The product is shown. FIG. At 0, the product 100 is a cylindrical element or body having a hollow central core 102. Consists of Day 101. A plurality of annular grooves 103 are formed in the outermost surface 104 and Increase the effective surface area of the Preferably, as shown in FIGS. Are provided on opposing tapered lands 105, which reinforce each groove and Ensures clean separation of mold 21 from element 101.   Such an annular groove 103 is machined into a cylindrical cartridge blank. The special process and associated waste material should be performed by compressing the components in a mold as described above. And removed by. Another advantage is that it provides an external surface other than a circumferential groove It is equally possible. By way of example, FIG. 12 shows a circle having a hollow central core 112. Another product 110 that provides a cylindrical body 111 is shown. The outermost surface 113 is It has a plurality of longitudinal grooves 114 extending axially over most of the length. Typical In addition, the groove disappears at each end 115 of the cartridge.   FIG. 13 shows a cylindrical body 121 and a central hollow core 1 according to another example of the external configuration. Given a plurality of dimples 123 having an inner surface 22 and being cut inward from an outer peripheral surface 124 The product 120 is shown. Of course, the overall configuration of the product is not limited to a cylindrical shape. Rectangle . Square or specific housing Other shapes configured to accommodate the inner volume of the ring In addition, it turns out that other external configurations are easily possible. Therefore, Light is a smooth external surface, ie, an uninterrupted cylindrical or relatively smooth No additional machining following manufacture, along with other surfaces provided by the mold surface It can be seen that the product has a discontinuous external surface, given by   It has a hollow core by increasing the density of the mixture of components in the closed-end mold. It is also possible to create tubular products that are closed at the ends. Such a structure is cylindrical As shown in FIG. 14 for a porous product 125 having a body 126, a core 128 and a closure base 129. Have been. Typically, this type of hollow tube product is prepared from a primary reinforcing medium. The binder is a hollow cylinder open at both ends. By using the method of the present invention , Such restrictions no longer exist.   According to the invention, it is also possible to prepare a multilayer cylindrical porous structure. FIG. Referring to FIG. 1, a bag 131, which is a rubber mold, is disposed in a hydraulic chamber 132. A pressure vessel 130 with is shown. The chamber is at the bottom by a ram 133 , At top, in mold opening 134 Is closed by a removable cover (not shown) received at Rubber mold Located inside is a hollow core 139 for the porous structure 140 (FIG. 16). With a cylindrical central mandrel 138, a plurality of cylindrical sleeves, for example 135 and 136.   Since the method of the present invention is suitable for the production of a solid porous structure, a mandrel is used. Is not critical for producing a porous structure, but the radial flow through the porous structure is To make hollow structures that are subsequently adopted when desired or necessary used.   As is apparent from FIG. 15, the sleeves 135 and 136 are coaxial with the mandrel 138. Yes, and allow the addition of three different combinations of components 141, 142, and 143 . The sleeve is first placed in the rubber mold 131, so that the three shells of the components are formed. The sleeve is retracted, the mold is closed and the components are high under pressure. Densified. The mold is subsequently opened and the raw product 140 melts the binder material. Removed through ram 133 for subsequent heating.   Referring to FIG. 16, a portion of a product 140 is shown, which is one type of medium. The outer layer 141 of the body, the intermediate layer 142 of another type of medium, and the medium different from the intermediate layer 142. Side layer , Which is the same or different medium as the outer layer 141. Generated products 140 Change or grade porosity from inferior to superior or superior to inferior The advantages are obvious given the fact that they can be done. Additionally, the binder -The particles, as is true for the other two components, such as the material and the raw strength reagent And different types of primary media such as fibers. Furthermore, the above explanation With reference to three distinct layers, two layers or less according to the invention. Indicates that a multilayer product providing three or more layers is possible.   As a modification, a multi-layer cylindrical porous structure can be prepared without using a sleeve. It is also possible. Referring to FIG. 17A, again the pressure vessel 130 is Shown with a bag 131 which is a rubber mold disposed within the I have. The chamber is closed at the bottom by a ram 133 and at the top into a mold opening 135. It is closed by the received removable cover 145 (FIG. 17C). Open mold When filling, a filler, filler 146, is inserted, which is described here. Distribute the coaxial layer of the synthetic medium such that   Filler 146 as shown has open base 148 and upper A portion of the funnel-shaped mouth 149 is provided. The filler 146 is, in these two examples, the present invention. Supplied with a source of a synthetic mixture according to. Filler 146 is included for simplicity Shown somewhat schematically and dispenses synthetic mixture into mouth and through filler It will be appreciated that the means for doing so are within the skill of those in the art and need not be shown. The filler 146 also provides two separate coaxial layers 152 and 153 of the synthetic mixture. , An outer wall 150 and an inner sleeve 151 are provided. Of course, only two layers are shown However, it should be understood that more layers are possible.   Filler 146 is first placed inside the bottom of the mold as shown in FIG. The mixture is carefully deposited inside the mold, so that layers 152 and 153 remain separate and separate It is. As it is slowly withdrawn (FIG. 17B), the compound flows inside the mold. Continuing, forming a pre-product essentially layered before densification. Filler 146 When the deposition has been completed, the flow is interrupted (by appropriate means not shown) and It is removed and a cover 145 is placed, followed by subjecting the mixture to isostatic pressing. After compression, the product 155 appears as shown in FIG. Is pulled out. Again, Mandre 138 is shown as a hollow structure, but a solid stratified structure Manufactured by removing.   Add layers added to cylindrical or other shaped structures already made By continuous compression, two or more zones of different properties can be obtained. It can be seen that a multi-layer product having layers or layers can be formed. This example shows Although not shown on the surface, a porous structure is formed by this method based on the above description. It is within the skill of the artisan, and therefore is alternatively included within the embodiments of the present invention. It is. Continuous compression adds additional layers or layers of synthetic material to compressed structure 155 Performed prior to being removed from the type, or After such removal in the structure, the structure is placed in another device or returned to the mold. You.   Additionally, the mixture of ingredients may be calendered or shaped such Flat sheets or layers, especially when densified by other means to provide A material is formed. Furthermore, adding the next layer of the component mixture on the first layer It is possible to create two-layer and multi-layer flat sheet products by means of such methods. This way It is possible to produce a product from a mixture of different basic components, One or more components that provide primary separation, reinforcement and binding capacity Has a specific blend of elements. The particular blend is the same as the other layers in the product Same or different. Also, such layers should have a smooth outer top and bottom. Have a surface, or they comprise grooves or other features, as described above.   Referring to FIG. 18, a device 160 is shown schematically, which is movable to provide a flat surface 162. It comprises a belt 161, which is driven by a motor 163. On face 162 There is a first hopper 164 that distributes a first type of media 165, which media is The blades or rollers 166 are arranged uniformly. 2nd hopper 1 68 is provided downstream from the first to distribute the intermediate layer medium 169, the medium The body is again placed evenly by the rollers 166. Further downstream, the third Thailand There is a third hopper 170 for dispensing the media 171 of the 6 evenly arranged. As a result, the product is illustrated to form raw product 172 Densified on the belt by means of no Formed.   In FIG. 19, a part of the multilayer flat product 175 is drawn in cross section, and a certain type of medium The first layer 165, the intermediate layer 169 of another type of medium, and the third layer A layer 171 is provided, the third layer medium being equal to or different from the first layer 165 medium. Cylindrical For a product 140 layered in shape, the resulting product 175 is from poor to good or good The porosity can be changed or graded from poor to poor. Additionally, different Primary media, binder materials and / or green strength reagents of any type may be employed. Again, while the above description has been described with respect to three distinct layers, it is in accordance with the present invention. Therefore, it is understood that a multilayer product providing two layers or three or more layers is possible. . Similar to the description given with respect to FIGS. 2B and 2C, the raw flat sheet product 172 is It is stamped into a plurality of disks or other shaped media. Already made flat structure The subsequent compression of the layer added to Can form multilayer products with more zones or layers. Call To do so, use another medium prior to heating following densification of all layers. It only requires a step of supplying a subsequent layer of the mixture. The additional layers are thus Or several layers of media may be added to the equipment It is added and densified in one process depending on the total.   From the above description of the fibrous component, the fiber is a single fiber as shown in fiber 180 in FIG. Or as fibrillated as shown by fiber 181 in FIG. Fibrils The fibrillated fibers 181 provide fibrils 182 extending outwardly from the strands 183. The fibrillated fiber is used for PM, GSA and binder where certain melting occurs. Useful as -B.   According to the preferred method of the invention, the primary medium is non-adsorbent or adsorbent (or adsorbent). Under several different compression and heating conditions based on Various porous structures are produced. Various combinations for manufacturing are shown in FIGS. 3A and 3 This is shown schematically in FIG. 9 main cases and different PMs for making non-adsorption , GSA and B material combinations are given in Table 2 when compressed and heated. There are four main cases for making adsorbed porous structures.   The O symbol indicates the presence of a component and it does not function as a binder. The M symbol is It indicates the presence of a component and it melts or reacts as a binder.     Case A1: The primary medium and the biostrength reagent do not melt or react. binder Only thawed or reacted. (Example 41)     Case A2: The primary medium does not melt or react. Raw Both the strength reagent and the binder melted or reacted. (Examples 21 to 23)     Case A3: The raw strength reagent does not melt. Both primary medium and binder melt Or reacted. (Example 42)     Case A4: Primary medium, biostrength reagent, and binder were all thawed. (Implementation Example 43)     Case A5: Either the primary medium or the binder acts as a raw strength reagent . Only the binder melts or reacts. (Example 44)     Case A6: The biostrength reagent melts or reacts. No binder is required. (Examples 17-20, if PE melts)     Case A7: Both the primary medium and the biostrength reagent melt or react. (Implementation Example 45)     Case A8: The primary medium melts or reacts. No binder is required. (Actual Example 46)     Case A9: Primary medium functions as a raw strength reagent and binder. (Example 4 7)   In another embodiment, a multi-component polyethylene sheath / polypropylene sheath is used. A fiber is used as the primary medium, but if the polyethylene sheath is heated, Upon melting, it acts as a binder. If no binder is present, Either PM and / or GSA must melt or react (case A6, A7, A8, and A9). Formulations with one or more PM, GSA, and B are shown in Table 2. Covered by a combination of nine basic cases. Adsorbable porous structure field The primary medium does not melt or react with other components, Only the different cases are observed for different combinations (Table 2).   Adsorbent porous structures, ie activated carbon media, reduce hiding useful surfaces To be made with a minimum amount of binder. However, non-adsorbent media Does not have these restrictions. Usually, high physical strength at high flow rates Are preferred. Non-adsorbent if higher physical strength is required The amount of binder relative to the medium is much higher than the amount used for the adsorbent.   If the medium needs binding power by melting or reacting with the binder If not, then make sure that the porous structure is held together to give the final strength. Reagents are required. Primary media (PM) and / or biostrength reagents (GSA) contribute to strength Cause. The porous structure is held together by tangled or deformed fibers and particles . There are two cases shown in Table 3 for each of the non-adsorption and adsorption media . Typical fine metal fibers and particles are ideal candidates for providing physical strength .   The O symbol indicates the presence of a component and it does not function as a binder.   To illustrate the practice of the present invention, a series of flip-flops will be described in detail in the following examples. The filter block is ready. All elements are by weight unless otherwise noted Expressed as a percentage.                             Example 1st to 20th   Fiberized fiber or polyethylene for green strength of carbon black The contribution of (PE) is to produce carbon, PE fiber and PE powder using the following components: Therefore it was proved.           85%: Carbon Bamebey & Sutcliffe type 3049, 80 × 325 mesh         4-15%: PE fiber (Minifiber, 13040F)         5-11%: PE powder (Quantum Chemical, FASP007)   As can be seen, the relative amounts of powder and fiber are a total of 15% by weight of polyethylene (PE). Yes, it changes in the first to twentieth embodiments. All the formed blocks 55 Each of which is formed in a block by a metal piston mold under various pressures. Typed. The mold adopted was 1.75 inches (7.78 cm) O.D. and 0.375 inches (0.953 cm) I.D. D. and the dwell time was 15 seconds. Length is about 2 depending on molding pressure They changed slightly by 5 percent, which was about 2.4 inches (6.10 cm). Raw The strength is at a rate of 0.0238 inch / second (0.0605 cm / second) perpendicular to the block axis. It is measured by compressing Of molding pressure and amount of PE fiber to green strength The effect is given in Table 4 and FIG. The four curves in FIG. Data points plot, each curve starting with 4% PE fiber and 15% Increase to percent. Each raw intensity can be read by curve and comparison. Can be.As is clear from Table 4, the higher the molding pressure, The green strength obtained is higher and for blocks made of 85% carbon The green strength is higher when the PE fiber increases. For the purposes of subsequent processing, these An acceptable green strength for the block is about 20 pounds.                            Examples 21-24   These porous structures (carbon blocks) were manufactured using the following components: .     4% PE fiber 13040F     11% PE powder FASP007     85% carbon Bamebey & Sutcliffe Type3049 carbon, 80 × 325 mesh   A mold of the same size as that used for Examples 1 to 20 was used, and the molding force was 8000 psi, dwell time 15 seconds and 2.25 inches long (except for Example 24) 5.72 cm) blocks were manufactured, Example 24 was manufactured by KX Corporation. 9.75 inch (24.77 cm) blocks, followed by 2.25 inch blocks disconnected. KX Corporation blocks have 85 percent carbon and 15 percent Consists of a binder for the paint. 0.625 inch (cut from 2.25 inch block 0.0238 inch / s for 1.588 cm) slice The crush test was performed by compressing at a speed of (0.0605 cm / sec). The block It has a 1.75 inch (4.45 cm) O.D. and a 0.375 inch (0.953 cm) I.D. Example 2 1 to 23 are calcined at 139 ° C. for the time intervals described in Table 5. Methylene chloride Removal evaluations were performed to evaluate the effect of the various blocks. Connecticut For a 300 ml / min feed stream of Meriden, a city water source, Tylene chloride was injected at a concentration of 300 ppb. Breakthrough concentration becomes 15ppb Was set as follows. After experiment, crush test cuts from 2.25 inch (5.72 cm) block 0.0238 inches (0.1535 cm) / sec for a 0.925 inch (2.350 cm) slice Implemented by compressing perpendicular to the axis at speed. The results of both tests are given in Table 5. Has been obtained.                           Examples 25-29   The same formulation employed in Examples 21-23 was 12 inches (30.48 cm) long. 290 gb with 1.75 inch (4.45 cm) O.D. and 0.375 inch (0.953 cm) I.D. Expanded to make a lock. The balanced compression method according to the preferred embodiment uses a rubber mold And compressed by 2500 psi water pressure for 20 seconds. The block continues Baking at 142 ° C to 143 ° C for various times and then 9.75 inches (24. 77cm). Three tests, Gram Life, Opaque Removal Effect and 0.6 AC Fine Test Dust (ACFTD) for specific particle removal rate in GPM Was adopted. Two 9.75 inches (24.K.) of KX Corporation from different lots 77cm) The product was evaluated (Examples 28 and 29). Crush testing is also performed and other tests are performed. The results are reported in Table 6.   The terms used in Table 6 are defined as follows.     a. ΔP: differential pressure (psid) across the filter at 0.6 GPM flow rate.     b. Gram Life ACFTD: When the differential pressure increases by 20 psi at 0.6 GPM flow rate, Cumulative weight (grams) of AC fine test dust (ASFTD) supplied to the container.     c. Turbidity NTU: Turbidity turbidity unit. Turbidity is a measure of the concentration and particle size of suspended solids in water. Function.     d. Removal rate of many particles between 1 and 5 microns: NSF (National Health Foundation) standard 42 Uses a minimum of 85% removal of this particle range for particle removal class 2 ratings.                            Examples 30 to 33   Utilizing the following components shown in Table 7, four porous structures (carbon blocks) produced. Length is about 2.42 inches (6.15 cm), O.D. is 1.75 inches (4.45 cm) and I.D. Was 0.375 inches (0.953 cm). The block is molded with 6,000 lbs. Baked for minutes. Radial airflow resistance is 0.625 (1.588) inch sliced donut shape It was measured at a constant airflow at a rate of 135 SCFH through the filter. In these examples For both PE fiber and powder melted as binder material and PP fiber reinforcement The effect is similar to that of Examples 31 to 33 (1 to 3% fiber) without fiber, ie, crush test. About 50 to 60 percent increase in final product strength as demonstrated by It can be seen by comparison with Example 30 which includes the following.                               Example 34   Utilizing 2000lbs of molding power and the following components, 55 gram blocks can be 2.4 inches (6 .1 cm) O.D., manufactured in a 0.75 inch (1.91 cm) I.D. metal mold.     85% diatomaceous earth (Grefco, Dicalite 6000)     6% PE fiber 13040F     9% PE fiber FASP007 The block was fired at 142 ° C. for 45 seconds.                                Example 35   The formulation and mold specifications of Example 34 are based on an additional 2.00 grams of resin Kymene 557H (Hercu les, 12.5% solids). The porous structure was fired at 142 ° C. for 45 seconds.                                Example 36   Utilizing 2000lbs of molding power and the following components, 55 gram blocks can be 2.4 inches (6 .1 cm) O.D., manufactured in a 0.75 inch (1.91 cm) I.D. metal mold.     80% diatomaceous earth (Grefco, Dicalite6000)     5% polypropylene (PP) fiber (MimiFiber Y600F)     6% PE fiber 13040F     9% PE powder FASP007 The block was fired at 142 ° C. for 45 seconds.                                Example 37   Utilizing 6000 lbs of molding power and the following components, a 55 gram block is 2.4 inches (6 .1 cm) O.D., manufactured in a 0.75 inch (1.91 cm) I.D. metal mold.     65% carbon type 3049     4% PE fiber 13040F     11% PE powder FASP007     20% diatomaceous earth (Grefco, Dicalite 6000) The block was fired at 142 ° C. for 45 seconds.                                Example 38   Using a 5000lbs molding force and the following ingredients, a 55 gram block is 2.4 inches (6 .1 cm) O.D., manufactured in a 0.75 inch (1.91 cm) I.D. metal mold.     85%: Consists of cured resin fiber and cellulose fiber, and sifts through 120-400 mesh Divided Cuno MicroKlean grinding dust     8% PE fiber 13040F     7% PE fiber FASP007 The block was fired at 143 ° C. for 50 seconds.                                Example 39   Using a force of 4000 lbs and the following components, a 20 gram porous structure is 2.4 in. H. (6.1 cm) O.D., manufactured in a 0.75 inch (1.91 cm) I.D. metal mold.     23.5% polypropylene fiber (Hercules, type T-153, 3 denier, 3mm)     15.5% PE fiber     1.5% PE powder FA700 (Quantum)     59.5% carbon type 3049 The porous structure was fired at 140 ° C. for 50 seconds.                                Example 40   Using a 6000 lbs molding force and the following components, a 15 gram porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     6.25% PE powder FA700     31.25% PE fiber 1304F     62.5% polypropylene fiber (Microfibers, NAT) The porous structure was fired at 141 ° C. for 45 seconds.                                Example 41   Utilizing 6000lbs of molding force and the following components, 55g porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     80% carbon type 3049     8% PP fiber (MiniFiber Y600F)     12% PE powder FA700 The porous structure was fired at 141 ° C. for 45 seconds.                                Example 42   Using a 6000 lbs molding force and the following components, a 20 gram porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     50% HDPE sheath / PP core multi-component fiber (BASF, B1657)     30% PP fiber (MiniFiber, Y600F)     20% PE powder FA700 The porous structure was fired at 141 ° C. for 45 seconds.                                Example 43   Using a 6000 lbs molding force and the following components, a 20 gram porous structure is 2.4 inches (6.1cm) O.D., 0.75 inch (1.91 cm) manufactured in a metal mold of ID.     65% HDPE sheath / PP core multi-component fiber (BASF, B1657)     25% PE fiber 13040F     10% PE powder FA700 The porous structure was fired at 141 ° C. for 45 seconds.                                Example 44   Utilizing 2000lbs of molding force and the following components, 15g porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     70% PP fiber (Y600F)     30% PE powder FA700 The porous structure is fired at 141 ° C. for 45 seconds.                                Example 45   Using a 6000 lbs molding force and the following components, a 20 gram porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     85% HDPE sheath / PP core multi-component fiber (BASF, B1657)     15% PE fiber 13040F The porous structure was fired at 141 ° C. for 45 seconds.                                Example 46   Using a 6000 lbs molding force and the following components, a 20 gram porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     80% HDPE sheath / PP core multiple components / fiber (BASF, B1657)     20% polypropylene fiber Y600F (MiniFiber) The porous structure was fired at 141 ° C. for 45 seconds.                                Example 47   Using a 6000 lbs molding force and the following components, a 20 gram porous structure is 2.4 inches Manufactured in a (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold.     100% HDPE sheath / PP core multiple components / fiber (BASF, B1657) The porous structure was fired at 141 ° C. for 45 seconds.                                Example 48   Utilizing 6000lbs of molding force and the following components, 55g porous structure is 2.4 inches (6.1cm) O.D., 0.75 inch (1.91 cm) manufactured in a metal mold of ID.     84% carbon type 3049     4% PE fiber (1304F)     1% PP fiber (MiniFiber Y600F)     11% PE powder FA700 The porous structure was fired at 141 ° C. for 45 seconds.                                Example 49   66 grams of Calgon TOGC carbon (80 x 325 mesh), 28.5 grams of Georgia Pacif A formulation consisting of ic GP phenolic resin powder and 3 grams of water is used in an Osterizer blender. For 30 seconds at minimum speed. Then add 13 grams of the mixture to 1.75 inches H (4.45 cm) O.D., 0.375 inch (0.953 cm) I.D., and 7/16 inch (1.11 cm) thick It was molded into a lock and fired at 130 ° C for 2 hours.                                Example 50   Using a 4000lbs molding force and the following components, donut-shaped 55-gram fill Is manufactured in a 2.4 inch (6.1 cm) O.D., 0.75 inch (1.91 cm) I.D. metal mold .     Made of 60% cured resin fiber and cellulose fiber, sieve through 200 mesh Split Cuno MicroKIean grinding dust     39.6% BTL melamine / formaldehyde resin powder, grade 412     0.4% citric acid (solid), 8% solution The porous structure was fired at 141 ° C. for 45 seconds.   The porous structures representing Examples 34 to 50 were tested against a KX 1M carbon block and 8 The radial airflow resistance is 0.625 inches (1.58 inches) of the filter donut. It is measured in a steady stream at a velocity of 50 SCFH through an 8 cm) slice.   The measured airflow resistance and crush force for Examples 34-50 are given in Table 8. I have.  Therefore, the method of the present invention is very effective for producing a porous structure. Is obvious. The invention is particularly useful for large separation (filter) media weights and relatively small Suitable for the production of carbon block structures such as filters with a low binder weight. But not limited to it. The method of the present invention can be used with various instruments and And component materials. Similarly, the separation medium according to the method is powdered. It does not need to be limited to carbon media. The shape of the porous structure of the present invention is a flat sheet. Limited to flat structures, cylindrical structures open at both ends or closed at one end Not just hollow, solid, virtually any geometrical structure Can be formed. Furthermore, the outer surface of the porous structure changes significantly.   Based on the above disclosure, the use of the method described herein will perform the above purpose Is obvious. Therefore, any obvious variations shall fall within the scope of the claimed invention. Therefore, the selection of particular component materials is dependent upon the invention disclosed and described herein. It is determined without departing from thought. In particular, the porous structure according to the present invention is not necessarily The blocks are not limited to those based on carbon, and the blocks are not necessarily in the shape of hollow core cylinders. Not limited No. Similarly, multilayer products are also included, which are derived from a mixture of one or more components. Issued, and it provides at least two different separating actions or properties. I Accordingly, embodiments of the invention include all modifications and variations that fall within the scope of the appended claims. No.

────────────────────────────────────────────────── ─── Continuation of front page    (72) Inventor Slowvark, Jack             89451, NV, Nevada, United States             Inn Village, Tiner Way             570

Claims (1)

[Claims] 1. A method for producing a porous structure, comprising:   Components that provide primary separation capability, components that provide green strength reinforcement capability, and binding capability And a component selected from the group consisting of thermoplastic and thermoset polymers; Forming a dry mixture comprising:   Distributing said mixture on a suitable surface and depositing to a desired thickness;   Densifying the mixture to a desired shape for the porous structure;   Removing the densified porous structure from the surface;   Up to about 20 ° C above the melting temperature of any of the thermoplastic components that provide binding capacity By heating the mixture at Combining, Consisting of: 2. A method for manufacturing a porous structure according to claim 1, wherein the forming step Includes the step of selecting the first, second and third components, each said component having said three capabilities. A way to bring one of the powers. 3. A method for manufacturing a porous structure according to claim 1, wherein the forming step Includes the step of selecting two of the three components, which together combine the three capabilities. The way of bringing. 4. A method for manufacturing a porous structure according to claim 1, wherein the forming step Is the one that provides the primary separation capacity, the green strength reinforcement capacity and the binding capacity. Wherein the step of selecting the components of 5. A method for manufacturing a porous structure according to claim 1, wherein the distributing is performed. The process wherein the step of densifying and the step of densifying are performed through a compression facility. 6. A method for manufacturing a porous structure according to claim 1, wherein the distributing is performed. The step of filling a mold with the mixture, and the step of densifying is self-contained. Equilibrium compression of the mixture into the shape of a porous structure having sufficient green strength to be supported The method that is performed by doing 7. A method for manufacturing a porous structure according to claim 6, further comprising the step of: Providing a mandrel into the mold prior to the adding step. 8. A method for manufacturing a porous structure according to claim 7, wherein the porous structure is formed. The shape of the body is cylindrical, And the porous structure is hollow. 9. The method wherein the shape has an L / D ratio of at least about 3: 1. 10. A method for manufacturing a porous structure according to claim 6, further comprising the steps of: In addition, at least a second dry mixture of the components around the porous structure may be And the step of isostatically compressing the second mixture around the porous structure Layered multi-layered material with sufficient green strength to be self-supporting. Providing a pore structure. 11. A method for manufacturing a porous structure according to claim 10, wherein the additional structure is used. An additional step is performed after the removal step, and further before the additional step. The method of claim 2, including the step of returning the porous structure to the mold. 12. A method for manufacturing a porous structure according to claim 6, wherein the porous structure is manufactured. Said shape of the structure is cylindrical and, additionally,   A mandrel and at least one cylindrical sleeve coaxial with the mandrel in the mold. Providing a leave, wherein the sleeve and the mandrel have separate volumes. Defining and dispensing the volume defined between the mold and the sleeve to a first component. Minutes of dry mixture, Further, the volume defined between the sleeve and the mandrel is defined as the first component. Filling with a dry mixture of different second components;   Removing the sleeve from the mold prior to the densifying step; Where the method includes. 13. A method for producing a porous structure according to claim 12, which additionally comprises: further   Providing one or more additional cylindrical sleeves coaxial with the mandrel A sleeve, wherein the sleeve additionally defines a separate volume; Fills the volume defined between adjacent sleeves with the dry mixture of the second component Roller process,   Removing the sleeve from the mold prior to the densification step; Where the method includes. 14． A method for manufacturing a porous structure according to claim 6, wherein the porous structure is manufactured. Said shape is cylindrical, and additionally,   Providing a mandrel in the mold;   Prior to the densification step, the volume defined between the mold and the mandrel is reduced. , Around the mandrel Filling the coaxial layer with at least a first and a second dry mixture of the components, A second dry mixture of said components different from said first; Where the method includes. 15. A method for manufacturing a porous structure according to claim 14, further comprising: In addition, the mold is provided around the porous structure with at least a third dry mixture of the components. Filling the second mixture around the porous structure. Layered porous structure having sufficient green strength to thereby be self-supporting Giving the body, Where the method includes. 16. A method for manufacturing a porous structure according to claim 15, wherein An additional step is performed after the removal step, and further before the additional step. Returning the pore structure to the mold. Where way. 17． 2. A method for manufacturing a porous structure according to claim 1, wherein said distributing step is performed. The step of applying the mixture on a flat support surface, and the step of densifying comprises: Distributed into one reduced thickness with sufficient green strength to be self-supporting Including the step of compressing the mixture. Mm, Where way. 18. A method for manufacturing a porous structure according to claim 17, further comprising: Further, prior to the densification step, at least a second dry mixture of Coating over the dispensed mixture of Where way. 19. A method for manufacturing a porous structure according to claim 17, wherein At least a second mixture different from the mixture obtained on the densified sheet. Applying the second dispensed mixture and the densified sheet. Compressed into layered sheet of reduced thickness with sufficient green strength to be self-supporting The process of Where the method includes. 20. 20. A method for producing a porous structure according to claim 19, additionally comprising: A step of cutting a porous structure having a desired shape from the sheet having a further reduced thickness. Including, including methods. 21. A method for producing a porous structure according to claim 1, comprising a primary separation ability. The components that provide power include carbon particles, diatomaceous earth, perlite, activated alumina, and silica. Selected from the group consisting of mosquitoes, zeolites, natural fibers and artificial fibers, Where way. 22. 22. A method for producing a porous structure according to claim 21, wherein The fibers are selected from the group consisting of cellulose, wool, jute, and hemp. The artificial varieties are polyolefin, polyester, carbon, graphite, glass. , Polyacrylate, rayon, nylon, aramid, multicomponent fibers and blends thereof Selected from the set of compounds Where way. 23. A method for producing a porous structure according to claim 1, wherein the green strength is enhanced. The above components which give a polyolefin, polyester, nylon, aramid, resin Fibrils selected from the group consisting of lyon and its mixtures and liquid biostrength reagents Is, Where way. 24. 24. A method for manufacturing a porous structure according to claim 23, wherein the liquid is used. Raw strength reagents include styrene-butadiene, poly (ethylene-vinyl acetate) and Ril latex; methylcellulose and hydroxypropyl methylcellulose , Carboxy methylcell Loose, hydroxyethyl cellulose; polyvinyl alcohol; polyvinyl -Pyrrolidone; polyacrylic acid; polyethylene oxide; polyethylene imine; Liacrylamide; natural rubber and its copolymers; water and one or more A method selected from the group consisting of a mixture comprising a liquid strength reagent as described above. . 25. A method for producing a porous structure according to claim 1, wherein the binding capacity is reduced. The thermoplastic and thermosetting polymer components provided are polyolefin, epoxy, Phenol-formaldehyde and melamine-formaldehyde resin powder and Selected from the group consisting of polyolefin fibers, Where way. 26. A method for producing a porous structure according to claim 1, wherein the cationic charge is charged. Electric resin, ion exchange material, perlite, diatomaceous earth, activated alumina, zeolite, Resin solutions, latex, metallic materials and fibers, cellulose, carbon particles, carbon fibers, Rayon fiber, nylon fiber, polypropylene fiber, polyester fiber, glass With concomitant reduction in the amount of fibers, iron and graphite fibers, and primary media About 0.1 to about 90% by weight Adding additional components selected from the set containing the encircled amounts of those mixtures. Including, Where way. 27. A method for producing a porous structure according to claim 1, wherein the pearlite is used. , Diatomaceous earth, activated alumina, zeolite, cellulose, rayon fiber, nylon Positively charging said additional component selected from the group consisting of fibers and carbon particles. Including additional steps, Where way. 28. 28. A method for manufacturing a porous structure according to claim 27, wherein said additional structure is provided. The step of positively charging the target component is performed before the forming step, and Including the additional step of adding a positively charged component to the mixture. Where way. 29. A method for manufacturing a porous structure according to claim 1, wherein the mixture is used. The desired shape created by the above process of densifying is a flat layer. the method of. 30. A method for manufacturing a porous structure according to claim 29, further comprising: Forming at least a second mixture of the components; and forming a flat layer. Densifying the second mixture to form a multi-layered product Assembling the layers as desired. 31. About 70 to about 90% by weight of the component providing the primary separation ability;   From about 1 to about 15% by weight of the component providing the raw strength reinforcing ability;   Selected from the group consisting of thermoplastic and thermoset polymers to provide binding capacity and About 8 to about 20% by weight of the ingredients A porous structure comprising: 32. 32. The porous structure according to claim 31, further comprising a cationically charged resin, Exchange material, perlite, diatomaceous earth, activated alumina, zeolite, resin solution, Tex, metal materials and fibers, cellulose, carbon particles, carbon fibers, rayon fibers , Nylon fiber, polypropylene fiber, polyester fiber, glass fiber, iron fiber From about 0.1 with concomitant reduction in the amount of graphite and graphite fibers, and primary medium An additional component selected from the set containing their mixtures in amounts ranging from about 90% by weight; A porous structure comprising: Where way. 33. 32. The porous structure according to claim 31, comprising a first, a second, and a third component. A porous structure, wherein each of the components provides one of the three capabilities. 34. 32. The porous structure according to claim 31, wherein the forming step is performed together with the three-dimensional structure. Selecting two of said three components to provide two capabilities; The porous structure. 35. 32. The porous structure according to claim 31, wherein one of said components comprises said primary component. A porous structure that provides release, said green strength reinforcement and binding capabilities. 36. 32. The porous structure of claim 31, wherein said component provides a primary separation capability. The components are carbon particles, diatomaceous earth, perlite, activated alumina, silica, and zeolite. Selected from the group consisting of natural fibers and artificial fibers, The porous structure. 37. The porous structure according to claim 31, wherein the natural fibers are cellulose, Selected from the set consisting of wool, jute and hemp; , Polyester, carbon graphite, glass, polyacrylate, rayon, Selected from the group consisting of nylon, aramid, multicomponent fibers and mixtures thereof. , The porous structure. 38. 38. The porous structure according to claim 37, wherein the component provides green strength reinforcement. Are polyolefin, polyester, nylon, aramid, rayon and their A fiber selected from the group consisting of a mixture of the above and a liquid biostrength reagent, The porous structure. 39. 39. The porous structure according to claim 38, wherein the liquid green strength reagent is styrene. Butadiene, poly (ethylene-vinyl acetate) and acrylic latex; Cellulose, hydroxypropyl methylcellulose, carboxymethyl Cellulose, hydroxyethyl cellulose; polyvinyl alcohol; polyvinyl Nyl pyrrolidone; polyacrylic acid; polyethylene oxide; polyethylene imine Polyacrylamide; natural rubber and its copolymers; water and one or more; Selected from the above set consisting of a mixture comprising a liquid biostrength reagent as described above, Porous structure. 40. 40. The porous structure of claim 39, wherein said thermoplastic provides binding capacity. The thermosetting and thermosetting polymer components are polyolefin, epoxy, phenol-form M Aldehyde and melamine-formaldehyde resin powder and polyolefin fiber Wherein the porous structure is selected from the group consisting of: 41. 41. The porous structure of claim 40, wherein said component provides a primary separation capability. Component is composed of carbon particles, and the component providing green strength reinforcement is polyolefin fiber. The thermoplastic and thermosetting polymer components which provide the binding capacity In many cases, consisting of fin powder, only the components that provide the binding capacity melt. Hole structure. 42. 41. The porous structure of claim 40, wherein said component provides a primary separation capability. Component is composed of carbon particles, and the component providing green strength reinforcement is polyolefin fiber. The thermoplastic and thermosetting polymer components which provide the binding capacity Consists of fin powder and melts only the two components that provide green strength reinforcement and binding capacity The porous structure of the place. 43. 41. The porous structure of claim 40, wherein said component provides a primary separation capability. The component is composed of multi-component fibers, said component providing the green strength reinforcement being polyolefin fibers. The thermoplastic and thermosetting polymer components which comprise fibers and provide the binding capacity are poly. Olefin powder Where the two components, which provide the primary separation and binding capacity, melt, Structure. 44. 41. The porous structure of claim 40, wherein said component provides a primary separation capability. The component is composed of multi-component fibers, said component providing the green strength reinforcement being polyolefin fibers. The thermoplastic and thermosetting polymer components which comprise fibers and provide the binding capacity are poly. A porous structure consisting of olefin powder, in which all three components are melted body. 45. 41. The porous structure according to claim 40, comprising a first and a second component, The first component provides the primary separation and green strength enhancing ability, and the second component Wherein said first component comprises polyolefin fibers and said second component comprises The component consists of polyolefin powder, in which only the second component melts. Hole structure. 46. 41. The porous structure according to claim 40, comprising a first and a second component, The first component provides the primary separation ability, and the second component provides the green strength reinforcement and Wherein the first component comprises carbon particles and the second component comprises A porous structure comprising olefin fibers, wherein only the second component melts. 47. 41. The porous structure according to claim 40, comprising a first and a second component, The first component provides the primary separation and binding ability, and the second component The first component is composed of multicomponent fibers, and the second component is Consisting of polyolefin fibers, where both the first and second components are molten Porous structure. 48. 41. The porous structure according to claim 40, comprising a first and a second component, The first component provides the primary separation and binding ability, and the second component The first component is composed of multicomponent fibers, and the second component is A porous structure comprising polyolefin fibers, wherein only the first component is melted object. 49. 41. The porous structure according to claim 40, further comprising a first component, wherein the first component comprises a first component. The component provides the primary separation, green strength reinforcement and the binding capacity, and the first component A porous structure comprising a multi-component fiber, wherein the first component melts. 50. 50. The porous structure according to claim 49, further comprising a cationically charged resin, On-exchange material, perlite, diatomaceous earth, activated alumina, zeolite, resin solution Liquids, latex, metallic materials and fibers, cellulose, carbon particles, carbon fibers, rayo Fiber, nylon fiber, polypropylene fiber, polyester fiber, glass fiber With an accompanying reduction in the amount of fibers, iron and graphite fibers, and primary media A small quantity selected from the group comprising their mixtures in amounts ranging from about 0.1 to about 90% by weight. Consisting of at least one additional component, The porous structure. 51. 51. The porous structure according to claim 50, wherein the perlite, diatomaceous earth, active Alumina, zeolite, cellulose, rayon fiber, nylon fiber and carbon particles Said additional component selected from the set of offspring is positively charged, Hole structure. 52. 32. The porous structure according to claim 31, comprising a flat layer. 53. 53. The porous structure according to claim 52, wherein the porous structure comprises multiple flat layers. A porous structure, each having a particular blend of said components. 54. 32. The porous structure according to claim 31, comprising a hollow-shaped structure. 55. 55. The porous structure of claim 54 having an L / D ratio of at least about 3: 1. 56. 32. The porous structure according to claim 31, comprising a plurality of coaxial layers, each of said layers. Is a porous structure comprising a molded structure having a particular blend of said components. 57. 57. The porous structure according to claim 56, wherein the molded structure is hollow. A porous structure having an L / D ratio of at least about 3: 1. 58. 32. The porous structure according to claim 31, comprising a molded structure having a hollow end closed. Structure. 59. 32. The porous structure according to claim 31, comprising a smooth outer surface. 60. 32. A porous structure according to claim 31 without separation machining following manufacture. A porous structure consisting of a given discontinuous outer surface. 61. 32. The porous structure according to claim 31, wherein the porous structure is a reinforced fiber. An improved raw material for a comparable porous structure without said components providing strength reinforcement A porous structure with strength. 62. 32. The porous structure according to claim 31, wherein the porous structure is a reinforced fiber. Improved end product strength for comparable porous structures without reinforcement such as A porous structure.